Apparatus and method for a reusable mailer

ABSTRACT

Embodiments of an envelope that is reusable and allows for efficient rerouting between intended recipients of the item in the envelope are disclosed. The envelope may be constructed of a durable material and may have various features that allow the envelope to be automatically sent via a carrier from one recipient to another. Thus, when a recipient of the item returns the envelope via the carrier, the envelope can be correctly processed and forwarded on to the next recipient with the same item, without the need of sending the item back to a return center or other entity. The term envelope generally includes envelopes, mailers and packages. Embodiments may include an envelope that facilitates multiple sorting and delivery cycles by the delivery service without the need for reconfiguration, repair, or replacement of the envelope.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/031,330, filed on Feb. 25, 2008. This application is also related to U.S. application Ser. No. ______, (ATTORNEY DOCKET NO. USPS.025A) filed on even date. The entire disclosure of each of the above applications is hereby incorporated by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

This disclosure relates to an envelope and systems and methods of processing the envelope for delivery of digital video discs (“DVD”)s, games, and other high value items through the mail or via any other delivery service for redelivery to a second recipient.

2. Description of the Related Technology

Many businesses send items to multiple customers. For example, movie rental services, such as DVD rental services like NetFlix, Inc. and Blockbuster, Inc., mail a DVD to a customer from a warehouse. Typically, these services use special purpose envelopes to send the DVD. When finished with the DVD, the recipient returns the item using these envelopes. Generally, these envelopes are good for only a single use.

In order to provide reasonable turn around times, rental services will maintain return centers that are geographically distributed. At these centers, returned movies are repackaged and sent to the next customer that has requested a particular DVD.

Unfortunately, this approach possesses inherent inefficiencies and challenges, and requires significant expense. For example, even with special purpose envelopes, it is difficult to efficiently process the shipping back and forth of the DVDs between the recipients and the return centers. It can also be difficult to locate and determine how to ship DVDs from the various return centers depending on the demand for various DVD titles.

SUMMARY OF CERTAIN INVENTIVE ASPECTS

The system, and devices of the disclosure each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this disclosure as expressed by the claims which follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of Certain Embodiments” one will understand how the features of this disclosure provide advantages that include an envelope configured for providing items to multiple recipients without being returned to the source and methods and systems of processing said envelope.

One embodiment comprises an envelope for routing an item from a source to a plurality of destinations, the envelope including at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the at least one sheet defines at least one opening for receiving the item into the pocket, wherein the sheet is configured to display an identifier associated with the item, a reusable closure configured to secure the item into the pocket; and a replaceable label identifying at least one of the destinations.

Another embodiment comprises an envelope for facilitating multiple sorting and delivery cycles to deliver an item to a plurality of recipients, comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the sheet defines at least one opening for receiving the item into the pocket; and a replaceable label identifying at least one of the destinations, wherein the sheet is configured to display an identifier associated with the item.

Yet another embodiment comprises a method for processing an envelope for routing an item from a source to a plurality of destinations, the method comprising: receiving an envelope comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the at least one sheet defines at least one opening for receiving the item into the pocket, wherein the sheet is configured to display an identifier associated with the item; and a reusable closure configured to secure the item into the pocket; and affixing to the envelope a replaceable label identifying one of the destinations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top level block diagram illustrating one embodiment of a system including a service provider and processing facility for delivering items to multiple recipients.

FIG. 2 a is a front perspective view of one embodiment of a suitable envelope for use in connection with the system of FIG. 1.

FIG. 2 b is a rear perspective view of the embodiment of an envelope of FIG. 2 a.

FIG. 3 illustrates a front plan view of another embodiment of an envelope for use with one embodiment of the system of FIG. 1.

FIG. 4 depicts a front view of another embodiment of the envelope without a flap closure for use with one embodiment of the system of FIG. 1.

FIG. 5 a is a front view of one embodiment of a suitable envelope including a front pocket and without a flap closure for use in connection with the system of FIG. 1.

FIG. 5 b is a front perspective view of the embodiment of the envelope of FIG. 5 a.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

The following detailed description is directed to certain specific embodiments of the development. However, the development can be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout.

Various embodiments of the disclosed herein provide an envelope that is reusable and allows for efficient rerouting between intended recipients of the item in the envelope. The envelope may be constructed of a durable material and may have various features that allow the envelope to be automatically sent from one recipient to another, for instance, by a U.S. Postal Service (“USPS”) processing center. Thus, when a recipient of the DVD returns the envelope in the mail, it can be correctly processed and forwarded on to the next recipient without the need of sending it back to a return center or other entity. The term envelope generally includes containers such as, but not limited to, envelopes, mailers and packages.

One embodiment includes an envelope that facilitates multiple sorting and delivery cycles by the delivery service without the need for reconfiguration, repair, or replacement of the envelope. Desirably, this permits expedited delivery of high value content to a series of recipients without the need to repackage the contents for each delivery. The envelope includes a durable outer component to survive multiple automated sorting and delivery cycles without damage. The envelope may also include an inner sleeve for the protection and identification of the content item during processing. The envelope also provides space for instructions, advertising, and other information required by the envelope.

FIG. 1 is a top level block diagram illustrating one embodiment of a system 100 that includes a service provider 102 and processing facility 104 for delivering items to multiple recipients 106. The service provider 102 maintains a database 108 that stores information about items requested by recipients. A dispatch control module 109 maintains request data in the database 108 and selects particular recipients to next receive particular items based on the request and item data stored in the database 108. The dispatch control module 109 may also control a dispatch facility 110 that processes requests by providing requested items in addressed containers and dispatching the containers to the address of the selected recipient 106. Each of the dispatch control module 109, the database 108, and the dispatch facility 110 may comprise one or more computer processors and associated software configured to perform the above-described functions. The dispatch facility 110 may also include container processing apparatuses operating under the direction of such processors.

The dispatch facility 110 of the service provider 102 provides the items in the containers to the processing facility 104 for delivery to the selected recipient 106. After use of the item, the recipient 106 returns the item to the container. In one embodiment, the recipient 106 removes an address label listing the address of the recipient 106 from the container to reveal a return processing address. The recipient 106 then dispatches the container (and the item disposed within the container) to the return address.

In one embodiment, the processing facility 104 reads an identifier associated with the item that is positioned in a viewing area of the container. The processing facility 104 recognizes that the identifier (or both) is indicative of processing according to the system 100. In one embodiment, the processing facility in addition, or alternatively, reads the return address on the container to recognize that the container is to be processed by the system 100.

The processing facility 104 communicates with the database 108 of the service provider 102 to determine the next recipient 106 of the item. The processing facility 104 readdresses the container to the second recipient and dispatches the container to the second recipient 106.

Referring now to FIGS. 2 a and 2 b, it is seen that a container, such as the envelope 200 comprises a planar sheet 202, a flap 204, and an opening 205 that forms a pocket 206 within the envelope 200. The envelope 200 further comprises reclosable closures 207 and 208, a viewing window 214 and a replaceable address label 216. The envelope 200 is configured to accept and retain the item 210 contained in a sleeve 212.

One embodiment of the envelope 200 has at least one planar sheet 202 which is configured to be folded to form the envelope 200. In other embodiments, the envelope 200 is formed by at least one sheet 202 that is glued or otherwise joined together. Envelope 200 is further configured to include a flap portion 204 which folds over the opening 205 and onto the envelope 200 to close the envelope 200. The flap portion 204 further comprises a reclosable closure device 207 and 208 of the envelope 200 to secure the envelope and its contents for multiple automated processing and delivery cycles. The closure device 207 and 208 permits easy access to the contents and simple handling of the envelope 200 by the recipient. The reclosable closure of the envelope 200 is accomplished with the use of hook and loop, zipper, zipper mechanisms, snaps or any other reclosable material that will withstand multiple reclosings. In the embodiment of FIG. 2 b, areas 207 on the flap 204 are made of hook material. In this embodiment, the areas 207 and 208 are circular; however they can be any shape. When the flap 204 is folded over the envelope 200 to close the envelope, the two circular areas 207 intersect with corresponding circular areas made of the loop material 208 that are located on the envelope. When the flap 204 is folded to close the envelope 200, the hook and loop sections come together and form the closure.

The opening 205 of the envelope 200 is located where the flap 204 folds over onto the envelope 200, forming a pocket 206. This opening 205 accommodates the placement within the pocket 206 of the inner sleeve 212. The inner sleeve 212 holds the item 210 which in this embodiment is, for instance, a DVD. The sleeve 212 can have a closure of the same mechanism as the envelope 200 or it can have a closure of adhesive, hook and loop, zipper material, etc. In some embodiments, the inner sleeve will contain the item 210 in a snug fit with no closure being necessary.

The envelope 200 also comprises a viewing window 214 and a replaceable address label 216. The viewing window 214 permits visibility of the unique contents identifier 215 on the inner sleeve 212 component for automated processing. The viewing window 214 may be any shape through which the item identifier 215 can be viewed. In some embodiments, this shape may be an oval or a rectangle. In other embodiments as discussed in FIG. 3, the viewing window is cross-shaped so that the item identifier can be read regardless of the orientation of the inner sleeve 212 within the pocket 206. In some embodiments the viewing window will be on the opposite side of the envelope 200 from that including the flap closure 204.

The replaceable address label 216 is configured to be replaced with a new address label by the processing equipment, as disclosed with reference to FIG. 1, in order to facilitate expedited processing to multiple recipients. The envelope 200 is then reintroduced into the process flow, in some embodiments this is the outgoing mail flow for quick and efficient delivery.

In one embodiment, the inner sleeve 212 or the item 210 in the envelope 200 has a permanent and unique barcode 215 adhered to its surface (referred to above as a “contents identifier”). The barcode 215 will be specific to the contents of the associated envelope 200. The barcode 215 is readily visible through the viewing window 214 of the envelope 200. The barcode 215 is indicative of an identifier that is stored and tracked in a database. Any service provider participating in the system and process of FIG. 1 is provided access to the database in order to update records as needed. This database may be updated based on the participating service provider's transactions. The information contained within the reference table may include a Unique Envelope Barcode “License Plate” (Table Key), the Recipient Account #, the Recipient Name, and Recipient Mailing Address.

In one embodiment, the envelope 200 is reusable and made of a durable material that is planar and slightly flexible so as to move through the processing machines without breaking or being damaged. Materials such as Mylar® by DuPont, Tyveck® also by DuPont, and cardboard are suitable and are used.

In some embodiments, the envelope 200 is made of an opaque or transparent material such that the bar code 215 of the item 210 placed in the pocket 206 of the envelope 200 may be scanned or processed without the viewing window 214.

One embodiment of the envelope 200 is configured to be re-usable and has the bar code 215 viewable though the viewing window 214 and visible for envelope processing machines as referred to in FIG. 1 to intercept such envelopes 200 as they are processed by the delivery service so that the envelopes 200 can be sent on to the next requesting recipient without incurring the time (and lost rental time) of being transported to the provider's warehouse for dispatch to a new recipient.

In some embodiments, the item identifier 215 is printed on both sides of the inner sleeve 212 so that it can be viewed through the viewing window 214 regardless of the orientation of the sleeve in the pocket 206.

FIG. 3 illustrates one embodiment of an envelope 300 with at least one barcode configured for use in the system and process of FIG. 1. The envelope 300 comprises at least one planar sheet 302 folded to form the envelope 300 with a flap 303, a reclosable closure 304, a pocket 305, a return address label 306, and a replaceable address label 310. The envelope 200 also includes an item identifier 215, an inner sleeve 212 and an item 210, as previously described.

In one embodiment, at least one planar sheet 302 is folded or joined together to create an envelope enclosure 300 with one overlapping edge that forms a flap 303 with a reclosable closure 304. The envelope 300 is configured to receive an inner sleeve 212 containing an item 210, for instance a DVD. The item identifier 215 appears on the inner sleeve 212 or in some embodiments directly on the item 210, or on both. The item identifier 215 can be a bar code.

In one embodiment, the viewing window 309 is located towards the top left side of the envelope 300 and is configured to show the identifier 215 that may be attached to the item 210. The viewing window 309 can be of any shape. In this embodiment, the viewing window 309 is a narrow rectangular window which is slightly greater than is the length of the item identifier 215. In some embodiments, the item identifier 215 will be placed on the inner sleeve 212 in more than one location so that the identifier 215 will appear in the viewing window 309 regardless of the orientation of the inner sleeve 212 within in the envelope 300.

The viewing window 309 may be a cutout or in some embodiments may have a plastic film over the opening. In some embodiments, the item 210 will only fit in the envelope 300 in one orientation so that the item identifier 215 is visible though the viewing window 309.

The envelope 300 has a replaceable address label 310 at the lower right hand corner of the envelope 300. The envelope 300 is configured to accommodate multiple address labels 310 to be affixed directly to the envelope 300 and removed from the envelope 300 by the recipient before being returned to processing. The address label 310 may include an adhesive suitable for withstanding the envelope processing equipment and subsequent delivery process while also being suitable so that the address label 310 can be peeled off of the envelope 300 by the recipient with no, or minimal, tearing or misalignment. In one embodiment, the area under the address label 310 is configured to have a permanent return address printed onto the envelope 300 so that if an address label 310 is inadvertently removed or skewed during the processing, transit time or while in a recipient's possession, a valid delivery address is available. In some embodiments, the envelope 300 has instructions printed on or provided within the envelope 300 for the recipient to remove the address label 310 before returning the item to be processed, for instance, before mailing.

FIG. 4 illustrates a front plan view of an envelope 400 configured for use in conjunction with the system of FIG. 1. As shown, the envelope 400 includes at least one planar sheet 402 that is folded to form the surface area of the envelope 400, a reclosable opening 404, an envelope pocket 405, a viewing window 412, return address label 414, and a replaceable address label 416. The envelope 400 is configured to receive an inner sleeve 212, an item 210, an item identifier 215, as previously described.

The envelope 400 is formed from a material such as cardboard, Mylar® or Tyvek®. The planar sheet 402 is folded to form the surface area of the envelope 400. In this embodiment, at least two of the edges align to make a reclosable opening 404 without a flap. The reclosable opening 404 opens to permit access to the envelope pocket 405. The reclosable opening 404 is configured to maintain the contents within the pocket 405. The reclosable opening is secured with a closure such as a zipper, a loop and hook closure or a snap closure.

In one embodiment, the inner sleeve 212 (FIG. 2 b) contains the item 210. In this embodiment, the item identifier is placed on the inner sleeve 212. In other embodiments, the item identifier 215 is placed directly on the item 210. In some embodiments, the item 210 is a DVD, or a video game. The inner sleeve 212 may have the item identifier 215 affixed to its outside surface in such an orientation that it lines up with the viewing window 412 of the envelope 400. In other embodiments the item identifier 215 is affixed directly to the item 210, for instance a DVD case, and the inner sleeve 212 has a viewing window similar to viewing window 412 through which the item identifier 215 can be viewed and which further aligns with the viewing window 412 of the envelope 400. In some embodiments, the item 210 is placed in the pocket 405 with no inner sleeve 212. The pocket 405 is configured to hold the item 210 and once the pocket 405 is closed to contain the item 210 therein.

The viewing window 412 can be virtually any shape, including a cross-shape so that the item identifier 215 can be viewed regardless of the orientation of the inner sleeve 212 within into the pocket 405. The viewing window 412 is configured to be a greater width than that of the item identifier 215 to account for movement of the inner sleeve 212 within the pocket 405 and to ensure that the item identifier 215 remains visible in the viewing window 412.

The envelope 400 comprises a return address 414 which may be located in the upper left-hand corner of the envelope 400. In the embodiment of FIG. 4, the envelope 400 comprises a replaceable address label 416. The current recipient of the item 210 will peel off the replaceable address label 416 before returning the envelope 400 to the mail. The permanent return address is printed on the area underneath the replaceable label 416. The replaceable address label 416 is read by the processing facility as described in FIG. 1, and if the processing facility determines that the envelope 400 is to be processes the processing equipment replaces the label 416 with a new replaceable label. The permanent return address is printed on the area underneath the replaceable label 416 in case a label application is faulty. In such a case, the envelope 400 would be returned to the envelope processing facility, thus preventing loss of the item.

FIGS. 5 a and 5 b depict embodiments of the envelope of FIG. 1, without a flap closure. FIG. 5 a is an illustration of an embodiment of the envelope with a pocket attached to the planar surface. FIG. 5 b is an illustration of the expanded pocket of the envelope. In this embodiment, the envelope 500 is configured by configured by folding or otherwise joining the at least one planar sheet 502 at the edges to create an envelope 500 with no overlapping edges. In other embodiments, the envelope 500 is made of a single planar sheet with no folds. The size of the envelope 500 may be dependent on the requirements of associated processing equipment and thus may correspond thereto. The envelope may be sealed on all sides and may not have an opening or may be a single sheet, as described above. The envelope 500 has a pocket 504 attached on one planar side of the envelope 500. In the illustrated embodiment, the pocket 504 is centrally located on one planar side of the envelope 500. The pocket 504 has an opening 507 (FIG. 5 b), without a flap, the opening 507 being configured to close the pocket 504 and contain the item 210 therein. The closure 506 of the pocket 504 is a reclosable closure 506, such as a zipper, a loop and hook closure or a snap closure.

The opening 507 of the pocket 504 can be expanded to receive the item 210 in the pocket 504. The pocket 504 is configured to hold the item 210 and once the pocket 504 is closed to contain the item 210 therein. The pocket 504 also has a viewing window 508 which is configured to permit viewing of the identifier 215 that may be attached to the item 210. The viewing window 508 can be of any shape. In some embodiments, the viewing window 508 will be a cross shape such that the item identifier 215 can be printed in two or more directions. The viewing window can be any other shape necessary to permit viewing of the identifier 215 regardless of the orientation of the item 210 in the pocket 504. The cross-shape is also beneficial with regard to the process described in FIG. 1 in that the identifier 215 can be viewed or processed by process machinery in several orientations of the envelope. In other embodiments, the envelope 500 is configured to have a reclosable opening, as previously described, either with or without a flap. In such an embodiment, the envelope is configured to receive documents or other items.

FIG. 5 b illustrates the pocket 504 in an expanded position. In some embodiments, the pocket is made of the same material as the envelope 500. In some embodiments, the pocket 504 material can be plastic or paper or other materials. In some embodiments, the item 210 is contained in an inner sleeve 212 before being placed in the pocket 504. If an inner sleeve 212 is present, the item identifier 215 may be located on the inner sleeve 212 as well as or in place of being located on the item 210. In some embodiments, the envelope material provides the support for the pocket 504 contents to be safely processed through the processing equipment.

In some embodiments, which includes the replaceable address label, a name and mailing address is printed by the processing system described in FIG. 1. In other embodiments, including an embodiment wherein all or a portion of the envelope is transparent, the processing machines described in FIG. 1, such as OCR and other address recognition devices, are used to image and process the image of a disc within the envelope to identify cracked or broken disks.

The envelope use and the associated methods and systems for its processing may be repeated for any number of items and for the same item in multiple return trips. Accordingly, the envelope and associated methods and systems for its processing reduce or eliminate the need for each and every item to be accounted for and redistributed at a distribution center. Instead, embodiments provide a “recipient-to-recipient” service that increases use of items such as DVDs that are processed through the service.

While the above detailed description has shown, described, and pointed out novel features of the disclosure as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the device or process illustrated may be made by those skilled in the art without departing from the spirit of the disclosure. As will be recognized, the present disclosure may be embodied within a form that does not provide all of the features and benefits set forth herein, as some features may be used or practiced separately from others. The scope of the disclosure is indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. An envelope for routing an item from a source to a plurality of destinations, the envelope comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the at least one sheet defines at least one opening for receiving the item into the pocket, wherein the sheet is configured to display an identifier associated with the item; a reusable closure configured to secure the item into the pocket; and a replaceable label identifying at least one of the destinations.
 2. The envelope of claim 1, wherein the envelope is configured to display an address of a specified destination when an address portion of the replaceable label has been removed.
 3. The envelope of claim 1, wherein the replaceable address label is configured to be removed by the recipient before dispatch.
 4. The envelope of claim 1, wherein the envelope has instructions printed thereon to remove the replaceable label prior to dispatch.
 5. The envelope of claim 1, wherein the replaceable label is used to re-route the envelope to a next recipient of the item during return processing of the item from a previous recipient.
 6. The envelope of claim 1, wherein the at least one sheet comprises a view area configured to display an identifier located on a sleeve enclosing the item.
 7. The envelope of claim 6, wherein the view area is centrally positioned over the contained item and is of a cross-shape, so as to display the identifier through the viewing window independent of the orientation of the sleeve relative to the envelope.
 8. The envelope of claim 1, wherein the replaceable address label is configured to be removed by envelope processing equipment.
 9. The envelope of claim 1, wherein the at least one sheet of planar material comprises a durable material.
 10. The envelope of claim 1, wherein the at least one sheet of planar material comprises a transparent material.
 11. The envelope of claim 1, wherein the pocket is configured to contain a computer readable medium.
 12. The envelope of claim 11, wherein the computer readable medium comprises one of a video game cartridge, DVD, computer storage tape and a compact disc.
 13. The envelope of claim 1, wherein the reusable closure comprises each of a hook and loop material.
 14. The envelope of claim 10, wherein the at least one sheet defines a flap configured to fold over at least a portion of one of the first and second sides of the sheet, wherein each of the flap and the sheet have one of the hook and loop material positioned so as to close the flap.
 15. The envelope of claim 1, wherein the reusable closure comprises an interlocking rib and groove.
 16. The envelope of claim 1, wherein the item will fit into the envelope in only one orientation.
 17. The envelope of claim 1, wherein the identifier is located on both sides of the item.
 18. The envelope of claim 9, wherein the durable material comprises at least one of cardboard, Tyvek®, and Mylar®.
 19. An envelope for facilitating multiple sorting and delivery cycles to deliver an item to a plurality of recipients, comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the sheet defines at least one opening for receiving the item into the pocket; and a replaceable label identifying at least one of the destinations. wherein the sheet is configured to display an identifier associated with the item.
 20. The envelope of claim 19, further comprising a reusable closure configured to secure the item within the pocket of the at least one sheet.
 21. The envelope of claim 19, wherein a return address is printed underneath the address label.
 22. An envelope for facilitating multiple sorting and delivery cycles to deliver an item to a plurality of recipients, comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the sheet defines at least one pocket for receiving the item into the pocket; a removable label identifying a first recipient, such that after removal of the label, information is provided on the envelope wherein a second recipient's information is identified; and a reusable closure configured to contain the item within the pocket of the at least one sheet, wherein the sheet is configured to display an identifier associated with the item, wherein the address label is configured to be replaced by envelope processing equipment, wherein the sheet comprises an viewing window configured to display the identifier, and wherein the identifier is located on a sleeve enclosing the item.
 23. An method for processing an envelope for routing an item from a source to a plurality of destinations, the method comprising: receiving an envelope comprising: at least one sheet of substantially planar material, having first and second sides configured with respect to one another to define a pocket configured to contain the item, wherein the at least one sheet defines at least one opening for receiving the item into the pocket, wherein the sheet is configured to display an identifier associated with the item; and a reusable closure configured to secure the item into the pocket; and affixing to the envelope a replaceable label identifying one of the destinations. 